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AD-E402  647 


Rsi|Kjrl  AHFSD<TR-93045 


*  2..  ••  i  --^4 


iD£D  EMGINEEBiMG  (CAE)  OVERVIEW 


Hagai  G.  Maira 


OTIC 

ELECTE 
JUN  2  9 1994 


2 


June  1994 


J.S.  ABMY  ARMAMENT  RESEARCH,  DEVELOPMENT  AND 

ENGINEERING  CENTER 


Fire  Support  Arrmments  Center 
^atinny  Arsenal,  Jersey 


Approved  lor  public  release;  distribution  is  unlimited. 


,p 


i98l0 


94  6  28  163 


The  views.  opixUons,  and/or  findings  contained  in  this 
report  are  those  of  the  authorsts)  and  should  not  be 
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1 .  AGENCY  USE  OM.Y  (leave  blank)  2.  REPORT  DATE  3.  REPORT  TYPE  AND  DATES  COVERED 

June  1994 

4.  TITLE  AND  SUBTITLE 

(X)MPUTER  AIDED  ENGINEERING  (CAE)  OVERVIEW 

5.  FUNDING  NUMBERS 

6.  AUTHOR(S) 

Hegel  G.  Neira 

7.  PERFORMING  ORGANIZATION  NAME(S)  AND  ADDRESSES(S) 

ARDEC,  FSAC 

Precision  Munitions  Division 
(SMCAR-FSP-E) 

Picatinny  Arsenal,  NJ  07806-5000 

8.  PERFORMING  ORGANIZATION 

REPORT  NUMBER 

Technical  Report 
ARFSD-TR-93045 

9.SPONSORING/MONITORING  AGENCY  NAME(S)  AND  ADDRESS(S) 

ARDEC,  IMD 

STINFO  Br.  (SMCAR-IMI-I) 

Picatinny  Arsenal,  NJ  07806-5000 

10.  SPONSORINGJMONITORING 

AGENCY  REPORT  NUMBER 

11.  SUPPLEMENTARY  NOTES 

12a.  DISTRIBUTION/AVAILABIUTY  STATEMENT 

Approved  for  public  release;  distribution  is  unlimited. 

12b.  DISTRIBUTION  CODE 

13.  ABSTRACT  (Maximum  200  words) 

Computer  aided  engineering  (CAE)  refers  to  a  collection  of  software  and  hardware  tools  integrated  into  a  system  (a 
computer)  that  is  providing  the  circuit  designer  and  circuit  troubleshooter  with  step-by-step  assistance  during  each 
phase  of  the  design  and  analysis  cycle,  as  well  as  during  development,  documentation,  and  maintenance.  Under 
the  CAE  umbrella  a  number  of  commonly  called  "automated  design  tools,"  which  are  the  software  components  of 
CAE,  are  revolutionizing  and  transforming  engineering  environments  from  the  "hands-on"  way  of  conducting 
business  into  a  virtual  or  simulated  "hands-on"  mode  of  operating;  and  are  having  a  tremendous  impact  throughout 
all  engineering  disciplines.  They  have  not  yet  displaced  breadboarding  and  other  methods  of  developing  circuit 
boards  yet  but  are  making  their  presence  known  to  the  point  of  being  totally  necessary  in  the  design  of  certain 
devices.  It  is  the  intention  of  this  report  to  promote  the  use  of  these  tools  in  the  government  by  providing  en¬ 
gineering  management  with  an  overview  of  the  hardware  and  software  products  available  for  electronic  simulation, 
while  covering  trends,  new  technologies,  and  costs. 

SUBJECT  TERMS 

Schematic  capture  Electronic  simulation  Spice  Sensitivity  Analysis 

Library  models  Workstations 

IS.  NUMBER  OF  PAGES  21 

16.  PRICE  CODE 

17.  SECURITY  CLASSIFICATION 
OF  REPORT 

UNCLASSIFIED 

18.  SECURITY  CLASSIFICATION 
OF  THIS  PAGE 

UNCLASSIFIED 

19.  SECURfTY  CLASSIFICATION 
OF  ABSTRACT 

UNCLASSIFIED 

20.  UMITATION  OF  ABSTRACT 

SAR 

NSN  7540-01  280-5500 


Standard  Form  208  (Rev.  2-89) 
Prescrired  by  ANSI  Std.  Z39-18 
298-102 


CONTENTS 


Page 

introduction  1 

CAE  at  Work  1 

Schematic  Capture  1 

Electronic  Design  and  Analysis  1 

Advanced  Computer  Technology  6 

New  Personal  Computers  6 

Workstations  8 

Responsible  Technology  8 

RISC  Architecture  8 

Justifying  and  Purchasing  1 0 

Systems  Costs  1 0 

Real  Benefits  1 1 

The  Purchase  Decision  1 2 

Conclusions  1 3 

Distribution  List  1 5 


Accesion  For 


NTIS  CRA&I 
OTIC  TAB 
Unannounced 
Justification 


8 

□ 


By _ 

Dist.  ibution  / 


Availability  Codes 


Dist 


m 


Avail  and/or 
Special 


INTRODUCTION 


In  Computer  Aided  Engineering’s  (CAE)  earlier  days,  only  selected  organizations 
in  large  companies  and  government  could  afford  the  systems  required  to  automate, 
design,  and/or  manufacture  an  end-item.  The  majority  of  midsize  and  small  or¬ 
ganizations  were  shut  out  from  taking  advantage  of  technologies  because  of  exor¬ 
bitant  costs  and  lack  of  qualified  personnel  to  help  them  undertake  such  transition. 
Breakthroughs  in  integrated  circuit  (1C)  technology  and  programming  have  now 
opened  up  the  doors  of  CAE  to  more  modest  companies  and  applications,  even  to  one- 
man  firms  and  hobby  electronics  enthusiasts. 

CAE  At  Work 

At  work,  the  simulation  of  an  electronic  circuit  in  a  CAE  system  begins  with  the 
schematic  capture  of  a  circuit,  where  a  complete  description  of  the  circuit  in  computer 
language  is  created  (often  times  called  a  ‘‘net-list”),  which  is  the  data  used  to  analyze, 
troubleshoot,  and  print  or  plot  the  results. 

Schematic  Capture 

Working  in  2-D,  designers  create  circuits  using  lines  and  component  models. 
Rather  than  redraw  a  component,  a  circuit  or  a  section  of  circuitry  used  in  other  areas 
can  easily  be  duplicated  using  the  copy  and  grouping  function. 

When  a  CAE  package  is  integrated  in  an  environment  where  parameters  and 
blueprints  are  constantly  changing  to  reflect  new  product  capabilities  and 
improvements,  modifications  are  quickly  made  without  having  to  recreate  the  entire 
drawing. 

These  and  other  techniques  accelerate  the  analysis  of  any  design  which  could 
include  a  large  number  of  subassemblies.  The  experience  in  many  companies  is  that 
productivity  had  doubled  since  the  systems  were  installed  (ref  1).  In  the  past,  en¬ 
gineers  worked  with  huge  drawings  that  made  the  analysis  of  a  particular  circuit  area 
very  cumbersome. 

Electronic  Design  and  Analysis 

Design  engineers  using  a  CAE  or  a  computer  aided  design  (CAD)  system  don’t 
have  to  depend  on  a  drafting  technician  to  present  a  layout  of  the  most  current  design, 
since  the  data  base  is  automatically  updated  every  time  a  circuit  modification  is 
performed. 


Applications  ranging  from  10  to  100.  to  1000  transistor  boards  can  be  simulated 
In  a  CAE  system  for  a  personal  computer  (PC),  where  the  number  of  transistors  that 
can  be  handled  is  constantly  increasing  as  prices  of  more  powerful  PC  drop.  The  limit 
is  10,000  discrete  transistors  at  a  time.  1991.  Although  there  are  other  discrete 
components  that  are  included  in  analog  and  digital  libraries,  the  number  of  transistors 
that  an  electronic  software  package  can  handle  is  a  figure-of-merit,  and  is  something 
to  look  at  when  choosing  a  CAE  package. 

Working  with  Simuiation  Packages 

A  simulation  package  can  not  as  yet  replace  the  engineer.  It  can  compute 
the  voltage,  the  current,  and  other  electric  parameters  at  virtually  any  point  in  the 
circuit,  but  it  can’t  communicate  to  you  exactly  what  to  do  with  them  or  how  to  achieve 
a  certain  response  from  the  circuit.  A  CAE  package  is  intended  as  a  design  aid  and 
will  do  only  what  it  is  asked.  The  right  questions  have  to  be  asked  before  every 
characteristic  of  the  circuit  is  known.  For  example,  in  power  dissipation  if  you  try  to 
dissipate  2  W  into  an  1/8  W  resistor,  the  simuiation  program  probably  would  not  raise  a 
flag,  but  will  give  you  a  value  if  a  query  is  made. 

This  example  is  not  100%  right.  As  a  matter  of  fact,  a  package  called  Smoke 
Alarm®i  will  now  raise  a  flag  (in  the  form  of  a  puff  of  smoke)  on  the  screen  next  to  the 
component  in  trouble,  to  indicate  that  it  has  exceeded  its  ratings.  Thereby  simulating 
the  actual  operating  constraints  of  the  circuit. 

An  electronic  simulation  program  will  also  warn  of  simple  problems  such  as 
short  circuits  and  other  extraordinary  conditions,  that  often  times  are  the  culprit  in 
malfunctioning. 

More  Simulation  Less  Breadboarding 

in  a  typical  design  cycle,  breadboarding  (physical  wiring  of  a  circuit  in  a  test 
board)  has  to  be  kept  to  a  minimum  in  order  to  produce  a  cost  effective  board,  which  in 
this  case  is  the  product.  The  optimal  process  is  to  use  simulation  at  various  times 
throughout  the  development  process  (trying  different  formats)  to  achieve  a  reliable, 
producible  design  that  meets  specifications.  Experienced  designers  advise  the  use  of 
some  level  of  circuit  simulation  in  the  early  design  stages  to  learn  more  about  the 
circuit  before  breadboarding.  For  the  case  of  high  bandwidth  components,  or  high 
frequency,  the  introduction  of  parasitic  inductance  and  capacitance  usually  requires 
the  construction  of  production  quality  prototypes.  Simulation  will  reduce  the  number  of 
time  consuming  breadboarding  iterations  required  to  complete  a  design. 


^Cadence  Design  Systems,  San  Jose,  CA. 


2 


The  consensus  among  engineers  using  CAE  packages  is  that  breadboar¬ 
ding  still  gives  a  closer  representation  of  the  final  circuit  for  low  frequency  designs,  but 
not  for  high  frequency  designs.  They  also  agree  that  simulation  works  well  in  some 
cases  but  not  for  others.  For  example,  simulation  for  designs  using  complimentary 
metal  oxide  semiconductor  (CMOS)  provides  a  good  correlation  to  the  hardware,  but 
bipolar  designs  do  not  offer  such  a  close  match. 

Spice  Simulation.  Most  analog  simulators  use  Spice^  or  a  derivative. 
The  newer  derivatives  are  constantly  improving  the  shortcomings  in  equation  conver¬ 
gence  that  the  original  had.  by  modifying  Spice’s  model  equations. 

Spice  simulates  a  device  using  both  modeled  equations  and  modeled 
parameters.  The  first  describes  device  types  and  technologies  [CMOS,  field  effect 
transistor,  transistor,  transistor  logic,  etc.],  and  are  part  of  the  simulation  software  and 
the  user  typically  cannot  modify  them.  The  second  one  models  specific  device  types 
within  a  technology  (from  data  books  e.g.  Sm.  im.  etc.).  THe  user  can  alter  these. 

Mixed-mode  Simulation.  Mixed-mode  simulation  (ref  2)  is  on  the  rise, 
with  more  than  a  few  vendors  now  offering  it. 

Because  even  systems  that  are  mostly  digital  systems  have  to  sooner  or 
later  interface  in  the  real  world  (the  analog  world),  both  analog  and  digital  simulation 
capabilities  are  needed  to  simulate  an  entire  system.  It  is  a  big  plus  to  have  the  two 
simulation  packages  integrated  into  one.  where  simulation  by  parts  is  no  longer  the 
only  means  to  accomplish  a  circuit  simulation. 

Mixed-mode  simulation  is  espedaily  important  for  circuit  designs  that  have 
feedback  paths  linking  analog  and  digital  circuits.  For  example,  motor  or  engine 
controls,  where  analog  sense  or  drive  circuits  and  the  control  equations  are  implemen¬ 
ted  digitally,  would  be  difficult  to  simulate  wnthout  mixed-signal  simulation.  Breaking 
up  the  analog  and  digital  sections  does  not  result  in  an  effective  simulation  of  the 
control  hoop. 

Mixed-mode  simulators  (ref  2)  typically  comprise  separate  analog  and  digital 
simulators  that  run  in  unison.  These  separate  simulators  need  the  net  list  split  into 
analog  and  digital  sections  before  they  can  run  the  simulation.  A  good  integration  of 
the  two  simulators  will  handle  the  net  list  split  internally.  The  separate  analog  and 
digital  simulators  operate  independently  except  when  an  analog  input  to  a  digital 
device  crosses  a  threshold  or  a  digital  input  to  an  analog  device  changes  state. 


ZBerkeley  Spice  created  in  May  1975  by  professor  L.  Nagel. 


3 


other  Simulation  Packages.  Simulation  packages  dedicated  to  specific 
design  specialties  are  becoming  widely  available,  and  should  ideally  be  compatible 
with  other  electronic  design  automation  (EDA)  software. 

Temperature-stress  analysis  packages  are  becoming  popular  in  en¬ 
gineering  environments  because  of  valuable  information  about  actual  working  thermal 
distributions,  in  military  applications,  where  working  temperatures  are  usually  higher 
than  for  commercial  applications,  it  is  usually  imperative  to  support  a  design  with 
considerable  analysis,  and  to  show  that  the  circuits  will  work  over  a  range  of 
temperatures. 

EEsof  and  Compact  Software  are  two  simulation  vendors  that  have  developed 
tools  dedicated  to  radio  frequency  (RF)  and  microwave  design.  These  packages  have 
extensive  military  applications  and  are  capable  of  covering  most  frequency  ranges. 

Analogy’s  SABER  is  a  simulation  package  that  is  more  than  just  an 
electronic  simulator  because  it  can  use  both  standard  electronic  device  models  and 
standard  mathematical  equations  to  define  elements  (electronic,  mechanical,  and 
chemical)  of  a  complete  system. 

Monte  Carlo  and  Sensitivity  Analysis.  Monte  Carlo  analysis  has  the 
ability  to  simulate  process-variations  (fluctuation  in  the  manufacturing  yield)  effects 
and  although  an  experienced  designer  will  design  a  circuit  to  minimize  these  effects, 
the  simulation  of  such  variations  can  result  in  a  better  design  evaluation. 

Sensitivity  analysis  is  used  to  tighten  the  performance  spread  of  a  circuit. 
This  simulation  package  will  help  to  determine  which  part  variations  have  the  most 
effect  on  a  circuit,  or  how  sensitive  the  circuit  performance  is  to  the  change  in  com¬ 
ponent  value.  Sensitivity  analysis  lists  components  starting  with  those  that  have  the 
most  effect  on  the  circuit,  and  calculates  the  worst-case  outcomes. 

In  system-level  circuit  design,  Monte  Carlo  and  sensitivity  analysis  will 
graphically  indicate  which  components  are  being  excessively  stressed;  and  in 
addition,  it  will  list  in  descending  order  the  percentage  of  time  that  each  component  is 
used  in  the  circuit  during  normal  operating  conditions.  This  knowledge  will  allow 
relaxed  performance  specs  and  still  meet  overall  performance.  It  would  also  prompt 
the  use  of  premium  parts  only  where  they  are  absolutely  needed  to  keep  cost  down 
and  increase  reliability  in  the  long  run. 

Library  Models 

A  simulation  package  is  limited  only  by  the  accuracy  of  the  models  that  are 
used.  In  the  early  stages  of  design,  a  simulation  package  enables  the  user  to  view, 
understand,  and  analyze  a  circuit’s  response  as  the  circuit  is  created.  The  use  of 
these  model  libraries  does  not  immune  anyone  from  related  modeling  problems.  A 


4 


few  things  need  to  be  kept  in  mind  when  using  these  iibraries,  i.e.,  if  the  necessary 
modei  parameters  are  not  avaiiable  in  the  library,  they  will  have  to  be  filled  in  from 
data  books  and  parametric  analyzers  (programs  that  help  find  the  optimum  parameter 
for  the  given  application  of  the  circuit).  Also,  when  a  part  is  modeled  for  a  specific 
application,  factors  can  be  included  that  are  important  to  that  modei.  For  example,  if  a 
quick  response  is  desired  from  a  threshold  detector  or  an  amplifier,  the  slew  time 
becomes  a  factor  that  should  be  closely  looked  at  and  modified  if  necessary  in  the 
library  models.  When  simulation  vendors  develop  parts  libraries,  they  have  to  satisfy 
everyone’s  needs,  which  can  result  in  models  that  are  a  compromise.  A  model  that 
oversimplifies  an  important  effect  being  sought  will  cause  trouble.  On  the  other  hand, 
a  more  detailed  model  will  always  make  the  simulation  run  slower.  In  addition,  there 
are  some  variations  in  the  quality  of  models  available,  so  an  assessment  of  the 
limitations  of  the  models  to  be  used  is  needed. 

Component  models  probably  present  the  biggest  problem  for  most  users.  In 
the  Military,  were  the  critical  components  are  custom  made  for  the  application  or 
project  at  hand;  the  biggest  problem  is  the  modeling  of  components  or  availability  of 
library  parts.  This  fact  alone  can  render  big  complex  simulation  packages  to  no  more 
than  a  “bali  park  figure  getter.”  The  solution  to  this  problem  is  to  contract  it  out  to 
simulator  vendors  or  companies  that  are  dedicated  to  the  modeling  of  electronic 
devices,  or  to  create  your  own  models  using  the  simulator’s  features  in  house.  The 
latter  needs  specialized  training  investment,  but  is  the  most  efficient,  cost  wise,  and 
rather  applicable  when  dealing  with  confidential  or  secret  parts. 

Model  needs  vary  greatly  from  user  to  user;  and  no  one  model  can  satisfy 
every  application,  because  a  give  device  can  be  modeled  at  several  different  levels  of 
complexity.  A  transistor  modei  may  have  less  than  a  dozen  or  as  many  as  several 
dozen  parameters  (a  graduate  level  electronics  test  book  (ref  3)  lists  23  parameters  for 
a  typical  bipolar  transistor). 

Valid  Logic  Systems  (now  Cadence  Design  Systems),  for  example, 
publishes  data  books  along  with  its  models  that  show  characteristic  device  curves. 
The  books  detail  what  effects  have  been  factored  in  and  those  that  have  not.  The 
system  permits  making  parametric  changes  quickly. 

As  new  devices  are  introduced,  simulation  users  must  either  obtain  or 
develop  models  of  the  devices.  The  best  solution  is  to  have  the  device  vendors 
provide  models  of  new  parts  as  they  are  introduced.  Needless  to  say,  device  vendors 
are  already  doing  just  that  since  it  makes  their  parts  more  attractive  to  the  even  larger 
community  of  designers  that  use  simulation  as  a  designing  tool. 


5 


ADVANCED  COMPUTER  TECHNOLOGY 


The  technology  that  promised  to  change  the  engineering  industry  as  we  know  it, 
is  delivering.  Constant  new  versions  and  new  generations  of  hardware  and  software, 
specially  in  the  CAD  arena,  are  commonplace  and  affordable  to  virtuai.y  all  en¬ 
gineering  organizations. 

New  Personal  Computers 

PCs  are  no  longer  a  weak  platform.  The  days  when  PCs  were  used  when  nothing 
else  could  be  afforded  are  history.  The  latest  and  more  powerful  PCs  offer  the 
processing  power,  graphics,  and  memory  that  are  required  to  tackle  a  good  share  of 
the  CAD  and  CAE  software  in  the  market  today. 

More  Powerful  Hardware 

After  the  introduction  of  PCs  in  the  mid-seventies,  the  computer  industry  has 
seen  many  changes.  Today’s  PCs  have  the  power  of  mainframes  of  not  too  long  ago. 
These  days  PCs  are  rather  inexpensive  if  compared  to  the  cost  of . . .  let’s  say,  sending 
someone  on  travel  for  a  few  days  or  buying  a  conference  chair.  PCs  lend  themselves 
well  to  expansion  and  upgrades.  More  memory  can  be  easily  added.  Faster  and 
higher  resolution  graphics  can  also  be  installed.  Lately,  some  manufacturers  have 
developed  adapted  versions  of  newer  generation  microprocessors  that  can  be 
mounted  in  old  computers;  more  specifically,  in  old  “mother-boards”  (main  electronic 
board  that  basically  contains  the  bus  system  and  the  microprocessor),  making  the 
upgrade  alternative  even  more  cost  effective. 

Expanded  memory  (more  RAM  readily  available  for  the  operating  system’s 
use  during  processing),  coupled  with  newer  and  better  operating  systems  like  Unix3 
and  operating  system/2  (OS/2)4,  that  are  capable  of  multitasking  (the  ability  to  run 
more  than  one  program  or  application  at  the  time),  are  making  PC-based  tools  the 
engineer’s  workhorse  for  even  more  complex  design  tasks. 

According  to  Byte  magazine  (ref  4),  there  are  more  engineering  groups  that 
have  bought  tools  that  run  on  an  IBM  PC  and  its  clones  than  any  other  platform. 

Automation  tools  for  PCs  are  relatively  inexpensive  when  compared  to  tools 
that  run  on  the  Sun,  Hewlett  Packard  (HP),  or  Silicon  Graphics  station;  and  automation 
tools  for  PCs  would  certainly  provide  a  training  vehicle  before  investing  far  larger  sums 
for  workstation-based  tools. 


30perating  system  developed  at  Bell  Labs  in  the  early  70’s  capable  of  addressing 
more  memory  at  a  time  than  DOS,  and  based  on  a  more  efficient  ‘higher  language, 
“C”’. 

^Similar  to  Unix  OS,  but  developed  at  IBM  in  the  early  80’s. 


6 


Vendors  of  workstation-based  engineering  design  automation  (EDA)  tools 
are  looking  to  these  new  powerful  PC  as  the  future  platform  for  their  software  package, 
and  as  a  way  of  reaching  more  and  more  engineers.  PSpice®s  and  MatLab®^  both 
have  versions  for  PCs  and  workstations  running  on  Unix. 

PC-based  tools  can  handle  the  same  types  of  design  tasks  as  workstation- 
based  EDA  tools  but  on  a  lower  scale.  They  can  handle  schematic  capture  or  drafting, 
logic  and  analog  simulation,  signal  processing.  1C  design,  and  PCB  design. 

Newer  Operating  Systems 

DOS  can  only  access  640  Kbytes  of  memory.  Because  of  this  memory 
addressing  limitation,  the  so  called  DOS  extenders  were  created.  They  allow  software 
developers  to  bypass  the  memory  limitation  and  make  full  use  of  the  32  bit 
microprocessor  machines  now  widely  available.  The  latest  generation  of  operating 
systems  like  OS/2  and  Unix,  also  Windows  NT,  for  new  technology  that  is  due  out  at 
the  end  of  1 993,  provides  multitasking  and  overcomes  the  serious  limitations  of  DOS. 
It  removes  the  640  Kbytes  barrier,  provides  16  Mbytes  of  addressable  memory  and  48 
Mbytes  of  virtual  memory  (memory  that  resides  in  the  hard  drive  but  is  looked  upon  by 
the  microprocessor  as  RAM  memory  available  for  the  operating  system  to  be  used 
when  application  programs. 

Powerful  Engines 

Central  processing  units  (CPU)  are  indeed  the  computer’s  engine,  and 
already  a  32-bit  CPU  based  machine  running  at  about  66  MHz  is  currently  available 
for  less  than  $15,000.00.  These  systems  are  more  than  25  times  faster  than  the 
original  PC  of  the  early  seventies.  Intel  and  Motorola  are  at  the  forefront  of  the 
microprocessor  race.  They  are  constantly  announcing  a  new  generation  of 
microprocessors  every  year,  breaking  new  grounds  in  transistor  density  and  proces¬ 
sing  speed.  The  Intel’s  80486  or  i486,  and  Motorola’s  68040  contain  over  one  million 
transistors.  The  next  generation  of  these  chips  is  rumored  to  contain  about  three  times 
as  many  transistors. 

Although  Intel-based  computers  or  IBM-compatibles  have  a  bigger  share  of 
the  PC  hardware  market,  and  of  the  software  market,  Apple  computers  are  promising  a 
good  fight.  Because  of  great  reviews  received  about  newer  micros  from  Motorola, 
Apple  computers  (which  use  these  new  micros  in  its  systems)  are  poised  to  stand  their 
own  ground  in  the  competitive  PC  arena  bringing  higher  powered  and  cheaper  units 
in  the  future. 


5A  mixed-mode  electronic  simulation  package  by  MicroSim  Corp. 

6A  mathematical  and  signal  processing  program  by  Math  Works  Incorporated. 


7 


Workstations 


Workstations  have  become  the  platform  of  choice  of  CAE  users.  The  machines’ 
multitasking  Unix  operating  system,  huge  memories,  built-in  networking  and  fast 
graphics,  along  with  usually  large  high  definition  (a  1024  by  760  pixels  is  considered  a 
high  definition  monitor)  monitors  make  them  ideal  for  CAE  applications. 

Workstations  are  known  for  their  ability  to  run  large  programs,  with  great  speeds 
(in  the  range  of  tens  of  millions  of  instructions  per  second),  having  virtually  all 
manufacturers  offering  network  and  interfaces  to  numerous  computer  environments. 
These  machines  can  also  be  enhances  by  adding  more  memory,  dedicated  graphics, 
or  floating  point  processors. 

Low-end  workstations  in  1990  could  be  acquired  at  a  price  of  about  $3,000  to 
$10,0007.  These  machines  are  often  monochrome,  and  are  used  for  drafting,  some 
electronic  design,  and  various  graphic  applications.  A  step  up  from  that  are  machines 
that  provide  color  and  have  faster  processors  equipped  with  at  least  32  Mbytes  of 
RAM.  These  usually  handle  3D  modeling  and  analysis  of  all  types.  They  sell  for 
$10,000  to  $30,000,  but  the  prices  are  less  than  a  year  ago  and  they  keep  coming 
down  due  to  stiff  competition  among  workstation  vendors  as  well  as  competition  from 
high-end  PC.  The  drop  in  unit  cost  is  perhaps  the  most  significant  development  in 
workstations  as  their  performance  continues  to  increase. 

Responsible  Technologies 

What  has  made  these  high  powered  computers  available  at  low  costs  are  two 
developments:  a  reduced  instruction  set  computing  (RISC)  architecture  and  an 
emphasis  on  user  interface  graphics  for  which  new  programming  techniques  and 
faster  hardware  are  responsible. 

RISC  Architecture 

The  developers  of  the  RISC  architecture  derived  the  fundamental  concepts  of  this 
design  philosophy  after  analyzing  millions  of  lines  of  existing  computer  code.  This 
analysis  testified  to  the  fact  that  most  of  the  software  in  use  at  the  time  (late  seventies) 
did  not  employ  the  then  de  facto  computer  architecture  complex  instruction  set 
computing  (CISC)  in  a  very  efficient  manner. 

The  term  reduced  instruction  set  computing  does  not  manifest  its  true  characteris¬ 
tics.  The  goal  of  a  RISC  architecture  is  not  to  reduce  the  number  of  executable 
instruction  in  Its  instruction  set  but  rather  to  speed  up  the  processing  by  making  the 


7AII  monies  from  FY  90. 


8 


compilers  (original  to  a  particular  computer  hardware,  it  is  a  program  in  read  only 
memory  that  is  the  intermediary  between  software  and  hardware)  and  processors 
match.  When  developing  RISC  architecture  developers  had  at  their  disposal,  due  to 
advances  in  the  field  of  electronics,  wider  bandwidths  at  higher  frequencies  and  faster 
memories  that,  along  with  the  newer  32  bit  CPU,  allowed  them  to  cram  more  infor¬ 
mation  in  every  instruction  with  the  objective  to  accomplish  an  instruction  of  a  fixed 
length  (32  bits)  with  every  cycle.  These  days  a  typical  RISC  architecture  machine 
would  usually  include:  a  single-cycle  instruction  execution,  a  fixed  length  instruction, 
larger  register  sets,  and  would  support  the  so  called  "high-level”  languages  like  Unix. 

In  a  CISC  processor  there  is  a  control  program  called  microcode,  which  interprets 
and  supervises  the  incremental  instruction  execution,  playing  the  role  of  "middle  man” 
between  the  compiler  and  the  CPU.  A  RISC  processor  has  no  microcode.  The 
machine’s  instructions,  now  crammed  with  more  information,  become  the  microcode. 
Consequently,  the  theoretical  achievement  is  one  instruction  per  clock  cycle;  however, 
no  pP  has  yet  attained  that  goal.  It  has  achieved  an  average  of  close  to  a  one 
instruction  per  cycle. 

X  Window  System 

As  workstations  become  more  popular  users  are  demanding  that  they  be  as 
easy  to  use  as  PC.  Vendors  of  these  systems  have  come  up  with  what  has  become  a 
standard  user  interface,  namely  X  Windows,  not  to  be  confused  with  Windows  from 
Microsoft. 


The  X  Window  standard,  in  simple  terms,  provides  a  method  for  displaying 
multiple  applications  simultaneously  on  screen.  At  the  same  time,  as  a  side  benefit,  it 
provides  one  with  a  standard  format  to  port  applications  to  other  systems. 

This  system  was  developed  at  the  Massachusetts  Institute  of  Technology 
(MIT)  with  assistance  and  support  of  Digital  and  IBM.  X  Window  is  a  network 
transparent  windowing  system.  This  means  that  X  Window  is  not  tied  to  any  given 
network  protocols.  In  turn,  this  means  that  you  can  run  applications  on  any  machine 
on  your  network  and  control  them  from  individual  windows  on  your  terminal.  These 
applications  doni  even  have  to  be  made  by  the  same  manufacturer  or  be  running  on 
the  same  operating  system.  They  just  have  to  be  in  your  network  and  running  X 
Window.  X  Window  is  basically  software  independent  at  the  user’s  graphical  display 
end. 


This  new  graphics  interface  promises  to  bring  the  look  and  feel  that  is 
common  to  all  workstations.  This  means  pull-down  menus,  dialog  boxes,  icons,  and 
other  elements  that  the  user  can  come  to  expect  from  every  application. 


9 


JUSTIFYING  AND  PURCHASING 


As  workstations  become  the  platform  of  choice,  the  abundance  of  ways  to  buy  a 
CAE  system  is  making  the  selection  process  more  complicated,  and  justifying  the  cost 
for  an  entire  CAE  system  is  not  easy.  This  technology  is  very  new,  and  as  such,  it 
produces  a  level  of  uncertainty  and  mistrust  in  management  levels  of  most  en¬ 
gineering  organizations. 

In  the  government,  as  in  most  engineering  organizations,  the  promise  of  an 
automated  solution  also  seems  and  feels  like  an  unlikely  proposition. 

The  requirements  in  a  military  scenario  are,  although  very  related  to  private 
industry,  a  bit  more  demanding  and  so  are  the  CAE  systems  to  be  justified  for  pur¬ 
chase. 

System  Costs 

CAE  has  costs  that  are  hidden  and  those  that  are  obvious.  The  sticker  price  of 
hardware  and  software  for  a  modest  system  is  in  the  tens  of  thousands  of  dollars.  Less 
obvious  are  expenses  for  maintenance,  training,  and  even  loss  of  productivity  during 
the  transition  period  to  an  automated  system. 

Initial  acquisition  costs  very  widely  depending  primarily  in  the  software  that  one 
intends  to  use  for  a  given  application.  The  hardware  part,  most  commonly  known  as 
the  platform,  is  usually  not  as  great  as  its  software  counterpart;  in  part  due  to  the  fierce 
competition  in  the  market  for  such  products  and  because  of  mass  production  of  key 
components  iiku  memory  chips  and  newer  generation  microprocessors  that  are 
becoming  common  in  the  market  place. 

Operating  Costs 

Annual  operating  costs  tent  to  follow  initial  acquisition  costs.  In  a  study  of 
300  firms,  conducted  in  1990  by  Practice  Management  System  Ltd.,  Newton,  MA,  it 
was  found  that  median  annual  operating  costs  were  $47,775.  These  costs  included 
hardware  and  software,  maintenance  and  upgrades,  system  operating  costs  of 
training,  and  other  costs  (space,  utilities,  insurance,  and  supplies). 

it  has  to  be  pointed  out  that  the  costs  of  a  CAE  system  are  specially  sig¬ 
nificant  when  considering  that  the  average  life  of  hardware  is  24  to  30  months.  This 
means  planning  ahead  for  replacing  a  updating  obsolete  and  outdated  systems. 


10 


User  Training 

This  in  an  important  but  often  neglected  element  in  the  purchase  decision. 
Organizations  often  succeed  in  selecting  a  good  system  from  a  reputable  vendor  at  a 
fair  price,  but  fall  short  in  budgeting  for  appropriate  training.  To  use  CAE  as  an 
effective  engineering  tool,  proper  training  available  from  different  sources  is  a  must  if  a 
CAE  system  is  going  to  be  something  more  than  a  “dust  collector. 

Vendors  of  the  software  to  be  used  are  usually  the  best  qualified  to  provide 
basic  and  advanced  training;  although  there  are  training  companies  that  can  provide 
training  for  almost  all  the  software  available  in  the  market.  Some  software  vendors 
have  on-going  training  on  advanced  concepts  that  are  usually  provided  for  an  extra 
fee. 


Upper  management  should  realize  that  one  or  two  training  courses  will  not 
produce  immediate  CAD/CAM/CAE  experts  but  will,  however,  give  employee’s  the 
confidence  to  go  on  learning  the  technology. 

Real  Benefits 

The  benefits  of  a  CAE  package  are  more  difficult  to  quantify  that  costs.  One  can 
easily  say  that  such  a  system  decreases  the  time  to  design  or  troubleshoot  a  circuit, 
but  it  is  more  difficult  to  say  by  how  much  and  what  cost  savings  that  implies,  or  how 
much  return  the  investment  is  paying-off.  The  payback  of  CAE  can  be,  and  usually  is, 
quantified  by  how  well  it  increases  productivity  or  how  significant  it  reduces  the 
product  development  cycle.  Processing  engineering  change  proposals  (ECP)  is  one 
way  in  which  engineering  groups  have  already  reaped  benefits  from  their  investment. 

it  should  be  understood  that  high  productivity  gains  are  not  going  to  be  ac¬ 
complished  by  acquiring  expensive  systems  and  using  them  for  drafting  or  just  simple 
ECP  processing,  it  is  in  design,  troubleshooting,  and  in  circuit  optimization  that  a  CAE 
package  gives  you  tangible  benefits. 

Another  well  defined  benefit  is  the  shortening  of  the  development  cycle.  Com¬ 
monly,  all  the  different  phases  of  development  are  performed  independently  and 
usually  involve  some  degree  of  effort  and  resource  duplication.  A  CAE  system  can 
take  the  task  of  putting  all  the  pieces  together  in  one  data  base.  This  would  shorten 
the  time  to  market  of  a  commercial  product  or  would  cut  the  time  of  first  fielding  in  the 
military.  It  is  indeed  this  ability  that  makes  a  CAE  system  a  vital  tool  in  all  engineering 
organizations. 


11 


Attention  should  be  focused  on  the  early  stages  of  the  design.  Design  for 
performance,  manufacturability/producibility.  and  concurrent  engineering  are  techni¬ 
ques  that  attempt  to  change  CAE  into  a  system  that  describes  costs,  features, 
specifications,  design  intent,  and  ranges  of  performances.  Also,  beyond  accelerated 
aging  models,  there  are  attempts  to  simulate  the  deteriorating  effects  of  dormant 
storage;  that  is  a  major  concern  in  the  Military. 

The  Purchase  Decision 

Seiecting  a  Vendor 

Standardization  of  hardware  platforms  has  benefitted  users  who  now  have 
more  choices  of  CAE  systems.  Most  companies  and  organizations  begin  the  process 
by  forming  a  CAE  acquisition  committee  which  requests  proposals  from  various 
vendors,  and  would  sometimes  bring  them  in  or  go  out  for  demonstrations  of  the 
packages  that  seem  to  fit  the  intended  applications. 

Vendors  would  then  come  back  with  questions  relating  to  the  company’s 
needs  and  practices.  Some  of  the  questions  may  include: 

•  How  many  users  (engineers,  technicians,  analysts,  drafters, 
programmers)  will  be  using  the  system? 

•  Are  you  a  research,  industrial,  or  a  military  concern? 

•  Do  you  have  an  Investment  in  existing  hardware  and  software  that 
will  need  to  be  taken  into  consideration. 

•  Are  other  corporate  or  organizational  divisions  using  CAE  equi¬ 
pment?  If  so,  what  kind? 

•  What  is  done  more  of:  electronic  analysis,  printed  circuit  board 
layout?  design  integrated  circuits,  millimeter  wave,  application  specific  1C  (ASIC),  etc.? 
statistical,  or  other  specialized  simulation  as  temperature  analysis,  or  VH  application 
specific  1C  (VHSIC)  and  hardware  description  language  (VHDL)? 

•  Are  you  interested  in  analog  or  digital  simulation?  both?  mixed¬ 
mode? 


•  How  much  time  or  what  percentage  of  time  is  spent  generating  new 
drawings?  revising  existing  drawings? 

•  What  is  your  procedure  for  generating  bills  of  materials  or  parts 
lists?  technical  illustrations?  bids? 

•  Finally,  and  invariably,  how  many  dollars  are  to  be  invested? 


12 


This  and  other  pertinent  information  heips  vendors  understand  the 
operation,  and  makes  it  possible  for  them  to  make  recommendations  on  the  optimum 
system  configuration  for  each  particular  need. 

Evaluating  Vendors 

It  is  important  to  buy  a  system  that  is  fast  enough  to  handle  the  needs  of  the 
intended  applications,  and  the  relative  speeds  of  the  hardware  to  be  acquired  will 
probably  have  to  be  discussed  using  ‘benchmarks’  as  figures-of-merit. 

Benchmarking  Systems.  Benchmark  tests  are  “canned”  programs  that  are 
used  for  measuring  computer  speeds.  These  may  or  may  not  demand  the  same 
capabilities  from  a  computer  that  the  applications  do;  therefore,  it  *  important  not 
to  select  a  vendor  based  solely  on  favorable  scores  of  formal  bene  <  tests. 

A  well  known  benchmark  figure  is  millions  of  instmetions  per  second  (MIPS). 
This  widely  used  number  is  the  rate  at  which  the  computer  can  move  bytes  of  infor¬ 
mation  around  and  perform  simple  arithmetic  on  them  like  addition,  subtraction,  and 
multiplication.  The  performance  of  a  DEC  VAX  1 1/780  as  1  MIP  has  become  a 
standard,  and  performance  in  MIPS  is  quoted  relative  to  it.  In  theory,  one  can  obtain 
this  value  by  multiplying  a  processor’s  average  instmetion  time  (AIT)  by  its  clock  rate, 
assuming  that  the  processor  operates  in  a  zero-wait-state  (given  that  the  processor 
does  not  have  to  wait  for  data  to  be  fetched  from  memory  and  that  it  has  all  the 
information  it  needs  readily  available  for  its  use)  environment.  Another  often  quoted 
benchmark  figure  is  the  Unpack,  which  measures  floating-point  performance  by 
having  the  computer  solve  a  100  x  100  algebra  matrix.  If  the  application  requires 
mostly  integer  manipulation,  a  fast  Unpack  rating  is  meaningless;  hence,  the  only  tmly 
useful  evaluation  of  a  computer  is  to  put  it  through  its  paces  processing  intended 
applications. 


CONCLUSIONS 

If  one  thing  can  be  said  about  a  computer  aided  engineering  (CAE)  system,  it  is 
that  it  had  thus  far  brought  results  to  the  great  majority  of  users  who  ventured  resour¬ 
ces  in  CAE.  Companies  of  all  sizes  report  increased  productivity,  reduced  design  and 
manufacturing  costs,  and  work  of  better  quality.  CAE  tools  are  the  fastest  growing 
applied  technology  in  the  world.  With  combined  sales  of  hardware  and  software 
projected  to  reach  the  10  billion  dollar  mark  by  1994  in  the  United  States  alone,  CAE 
and  design  is  one  of  the  leading  causes  of  profit  reinvestment  in  industry,  and  a  major 
source  of  new  white-collar  employment. 

It  is  anticipated  that  in  the  immediate  future  hardware  will  be  sold  directly  by 
computer  vendors  or  their  dealers.  The  most  popular  operating  systems  will  be  the 
ones  available  for  multiple  platforms.  Specialized  applications  software  will  be  sold  by 
its  developers,  and  some  may  be  sold  by  computer  vendors. 


13 


What’s  in  store  for  CAE  in  the  90s?  More  changes.  For  instance,  ‘open’  systems 
will  dominate  making  fiies  easily  accessible  regardless  of  platform.  The  newly 
implemented  computer  aided  design  (CAD)  framework  initiative  (CFI)  expects  to 
define  a  fuiiy  integrated  electronic  design  automation  (EDA)  environment.  In  this 
environment,  toois  from  different  vendors  will  work  together.  Every  tool  will  have  the 
same  look  and  feel.  Although  CFI  appears  free  of  problems,  it  still  has  some  critical 
aspects  to  work  out.  When  the  electronic  design  interchange  format  (EDIF)  was 
demonstrated  at  the  1988  design  automation  conference  (DAC),  severai  vendors 
proved  it  was  possible  to  pass  design  information  from  one  vendor’s  tool  to  another. 
All  the  designer  needs  it  an  EDIF  writer  to  translate  design  information  from  one  EDA 
vendor’s  format  into  EDIF,  and  an  EDIF  reader  to  translate  design  information  into  the 
EDA  vendor's  format.  Problems  arise  when  vendors  support  reading,  but  not  writing 
EDIF.  In  other  words,  vendors  support  the  flow  of  information  into  their  environments 
from  other’s  vendors’  tools,  but  users  can  not  transfer  design  information  out  to  use 
with  competitor’s  toois.  At  this  point  in  time  there  are  more  EDA  companies  supporting 
only  and  EDIF  reader,  and  not  an  EDIF  writer. 

The  affordable  price/performance  ratio  of  workstations  and  personal  computers 
(PC)  has  brought  new  users  into  the  market  at  ail  levels  and  users  in  the  industry  as 
weil  as  in  the  Government,  have  a  wide  selection  of  platforms,  operating  systems,  and 
engineering  software. 

The  electronics  industry  is  not,  by  any  means,  the  only  one  that  has  benefitted 
from  the  CAE  technology;  as  a  matter  of  fact,  virtually  100%  of  all  industries  have  been 
touched  or  influenced,  for  the  better,  by  the  CAE  revolution.  In  the  mechanical  and 
electronics  industry  the  applications  are  even  more  infiuential.  to  the  point  that  none  of 
these  businesses  couid  survive  and  thrive  in  the  highly  competitive  industrialized 
world  without  the  aid  of  CAE. 


14 


DISTRIBUTION  UST 


Commander 

Armament  Research.  Development  and  Engineering  Center 
U.S.  Army  Armament,  Munitions  and  Chemical  Command 
ATTN:  SMCAR-IMI-I  (3) 

SMCAR-FSP>E,  H.  Neira  (10) 

SMCAR-GCL 

Picatinny  Arsenal.  NJ  07806-5000 
Administrator 

Defense  Techni^l  Information  Center 
ATTN:  Accessions  Division  (12) 

Cameron  Station 
Alexandria.  VA  22304-6145 

Director 

U.S.  Army  Material  Systems  Analysis  Activity 
ATTN:  AMXSY-MP 

Aberdeen  Proving  Ground,  MD  21005-5066 
Commander 

Chemical/Biological  Defense  Agency 

U.S.  Army  Armament.  Munitions  and  Chemical  Command 

ATTN:  AMSCB-CII,  Ubrary 

Aberdeen  Proving  Ground,  MD  21010-5423 

Director 

U.S.  Army  Edgewood  Research,  Development  and  Engineering  Center 
ATTN:  SCBRD-RTB  (Aerodynamics  Technology  Team) 

Aberdeen  Proving  Ground,  MD  21010-5423 

Director 

U.S.  Army  Research  Laboratory 

ATTN:  AMSRL-OP-CI-B,  Technical  Library 

Aberdeen  Proving  Ground,  MD  21005-5066 

Chief 

Benet  Weapons  Laboratory.  CCAC 

Armament  Research,  Development  and  Engineering  Center 

U.S.  Army  Armament,  Munitions  and  Chemical  Command 

ATTN:  SMCAR-CCB-TL 

Watervllet,  NY  12189-5000 

Director 

U.S.  Army  TRADOC  Analysis  Command-WSMR 

ATTN:  ATRC-WSS-R 

White  Sands  Missile  Range,  NM  88002 


15